A spindle sander is something I have never had in my workshop, although I can see the benefits of having one, in the past I have used a multi-tool with the drum sanding attachments, but at the moment, I haven’t even got one of those, and needed to make a circular cut, just a fraction bigger.
It is all too easy to set to, and find that you end up with a misshapen circle, but there is a simple option:
all you need is a length of dowel (slightly smaller than the circle), or in my case the remains of a spade shaft, spray glue, and some sandpaper, fortunately I had all these sitting around the workshop.
I cut the wood to size,using my sliding mitre saw, and then cut a kerf along the section for the sandpaper, again using the same saw.
cut the sandpaper to size, (I just cut it off a roll) finally, spray both the dowel and the sandpaper with glue, and attach the sandpaper, inserting the ends into the kerf, this avoids any problem with the circle being distorted by a seam.
To remove the sandpaper, use a hot-air gun, or the wife’s hairdryer to soften the glue, and peel off.
For my next version, I think I would cut the wood longer, and have a handle on each side of the sandpaper, to allow even pressure when sanding, and you could always cut the kerf the entire length of the dowel.
However it works, and it’s a darn site cheaper than a spindle sander, even if it does take a bit longer to get the end result!
-- If you want the rainbow, you got to put up with the rain - Steven Wright